Multi-colored composite foil of thermoplastic synthetic material and method and device for its manufacture

ABSTRACT

The invention concerns a multi-colored composite foil ( 14 ) of thermoplastic synthetic material and a method and a device for its manufacture. The device according to the invention comprises a first extruder device ( 20 ) with a first forming tool ( 22 ), whereby the extruder device produces a first plastified synthetic material melt and extrudes same by the first forming tool in order to manufacture a carrier foil or carrier layer ( 10 ) with a first color ( 28 ) and with a depression.  
     The device can, furthermore, comprise at least one second extruder device ( 24 ) with a second forming tool, whereby the second extruder device produces a plastified synthetic material melt and extrudes same by means of the forming tool in order to produce a top foil or top layer ( 12 ), which has a second color and which fits, surface-flush, into the depression of the carrier layer or carrier foil. The device according to the invention has, in addition, a calender ( 32 ) which joins the carrier foil, surface-flush, with the top foil fitted into the depression of the carrier foil under the influence of pressure and heat and which flattens out the produced surface.

[0001] The present invention concerns a multicolored, specifically atwo-colored foil of thermoplastic synthetic material and a method and/ora device for the manufacture of the multicolored plastic foil.

[0002] Two-colored plastic foils are employed for example in motorvehicle technology as linings and surfaces for dashboards, interior rooflinings or interior door panellings.

[0003] A two-colored dashboard foil or armature board foil of this typeis described in DE 195 30 757 A1. The known foil consists of a sub-foiland at least two top foils, which have different colors and which areplaced next to each other onto the plane sub-layer in order to form atwo-color composite foil. The known dashboard foil is manufactured byco-extrusion of multiple extrusion of sub-layers and the two top layers,whereby a separate extruder is used for each of the layers. Theplastified synthetic melts produced by the individual extruders arepassed to an adapter block, which initially forms the individual layersseparately, then joins same and finally discharges the combined layersvia a sheet orifice. Consequently, in order to manufacture the knowntwo- or multicolored plastic foil, at least three extruders are needed,which must be charged and controlled simultaneously. Moreover, inmanufacturing the known foil, the reject rate is increased due to thegreat number of adjacent surfaces, for example for a two-colored foil,three adjacent surfaces between the different layers, where, forexample, objectionable air-or gas bubbles can be occluded during thejoining of layers, as well as other border area problems, which mayoccur for example based on minor differences in the properties of thesynthetic materials employed for the individual layers.

[0004] It is the object of the present invention to provide a simplemethod for the manufacture of a two- or multicolored composite foil ofthermoplastic synthetic material, with which it is possible to overcomethe cited drawbacks of the state of the art. Furthermore, it is theobject of the present invention to make available a device forimplementation of the method. Another object of the invention lies inmaking available a two- or multicolored composite foil of thermoplasticsynthetic material, which is easy to process further.

[0005] These objects are solved by the method according to claim 1, andalso by the device according to claim 7 and the composite foil accordingto claim 19.

[0006] The method according to the invention in accordance with claim 1for the manufacture of the multicolored, specifically two-colored,composite foil of the present invention comprises accordingly themanufacture of a carrier foil or carrier layer by extrusion of athermoplastic synthetic material, whereby the carrier foil or thecarrier layer has a least one depression or recess or indentation in itsthickness profile.

[0007] The term depression in this context specifically means anydeviation in the thickness profile of the carrier layer from itsrectangular form. The depression can for example have the form of arectangularly shaped recess or a rectangular cut-out from arectangularly shaped contour. The cross-sectional contour passes at onetop side of the carrier layer in form of a step into the depressed areaof the recess. The depression can occupy one single closed area of thecarrier foil, it can, however, also involve several, from each otherseparated, areas of the carrier foil.

[0008] Concurrently with the manufacture of the carrier layer, in themethod according to the invention, at least one top foil or top layer isconducted, whereby the top layer or the top layers fits (fit) into theappropriate depression of the carrier layer and is/are positioned insuch manner in the depression of the carrier layer or carrier foil, sothat the thus obtained multicolored plastic foil of the invention isformed with flush surface, whereby the carrier layer has a differentcolor or is dyed differently than the top layer or the top layers. It isalso possible to guide several top layers or top foils from differentlydyed synthetic materials.

[0009] The plastic foil or deep-drawn foil according to the inventionproduced with this method according to claim 19 has one top side andconsists of a composite of one carrier layer or carrier foil and atleast one top layer or top foil, whereby the top layer or top foil isfitted into a depression of the carrier layer or carrier foil and isflush with the surface of the carrier layer or carrier foil and thecarrier layer or carrier foil and the top layer or top foil each formpart of the top side of the foil and each have a different color shade.

[0010] The foil according to the invention preferably has a rectangularthickness profile, whereby the depression of the carrier foil or carrierlayer is a rectangular recess and extends into the top foil or top layerarranged in the rectangular recess at the top side of the foil.

[0011] If one examines the top side or the upper surface of the finishedfoil of the invention, one sees, for example, with a two-colored foil,an area with a first color and an area with a second color. The firstvisible surface area belongs for example to the carrier layer and thesecond visible surface area is then a component of the top foil or toplayer. The first color can have a dark, black or gray color shade whilethe second color can have a light or white shade of color.

[0012] Since the carrier layer or the carrier foil itself is visiblewith employment of the foil according to the invention, at least oneextruder is saved by means of the present invention vis-a-vis the stateof the art, as a result of which a most cost efficient and easiercontrollable method is obtained for producing the multicolored foilaccording to the invention. In addition, less waste is generated in theproduction of the foil according to the invention, since, for example,with a two-colored foil, which, according to the invention is composedof one carrier layer and only one top layer, there exists only oneborder area, compared with the above explained state of the art, whichis technologically easier to control, as a rule, and contributes toreduced faulty production at the border areas, and thus to lower rejectmaterial.

[0013] Finally, it should be pointed out that, overall, the foilaccording to the invention has improved stability when applied orfurther processed, inasmuch as due to the minimal layer- and border areanumber, defects in the border area are also minimal.

[0014] The synthetic material from which the carrier layer or thecarrier foil is made and the plastic material or plastic materials fromwhich the top layer or the top layers is/are made preferable haveapproximately the same viscosity at the same temperatures. Because ofsaid property, a stable compound of carrier layer and at least one toplayer or top foil is obtained during manufacture of the foil accordingto the invention.

[0015] Suitable thermoplastic synthetic material for the methodaccording to the invention are, among others: polyolefins,vinylpolymers, polyamides, polyesters, polyacetates, polycarbonates and,partially, polyurethanes as well. Specifically preferred arepolyolefins.

[0016] The polychromacity of the plastic foil according to the inventioncan be obtained by adding suitable different color pigmentation or dyeto the plastic melts of the carrier layer or the carrier foil and thetop layer or top layers.

[0017] The device according to the invention for the manufacture of thefoil according to the invention having two or more colors according toclaim 7 comprises one extruder device for producing a plastifiedsynthetic material melt, said extruder device being equipped with afirst molding tool for molding a carrier foil or a carrier layer of afirst color while forming at least one indentation.

[0018] It can have, in addition, at least one other extruder device forproducing at least one additional plastified synthetic material melt,whereby at least the one additional extruder device is equipped with oneadditional molding tool for molding a respective top foil or top layerwith a color different from the named first color, whereby at least theone additional molding tool is designed in such manner that the surfaceof the therefrom formed top layer or top foil respectively fitssurface-flush into the corresponding depression of the carrier layer orcarrier foil.

[0019] Furthermore, the device has a calender for surface-flush joiningof the carrier foil or carrier layer with at least the one top layer ortop foil fitted into the corresponding depression of the carrier layeror carrier foil and for smoothing out the produced surface.

[0020] The first molding tool preferably has a slot-like orifice, intowhich projects a protrusion, whose cross-section extending cross-wisevis-a-vis the flow direction of the plastic melt corresponds to thecross section of the depression of the to be produced carrier foil.

[0021] Said protrusion may be arranged adjustably in the first moldingtool of the device according to the invention in order to be able tochange or adjust the shape or the dimensions of the depression in thecarrier foil or the carrier layer.

[0022] The protrusion can have the shape of a relatively elongated lipor lamella, which extends over a portion of the slot-like cross-sectionof the orifice of the first molding tool. It is possible, hereby, tothus produce a depression or recess in the carrier layer which isrectangular in cross-section.

[0023] The lip may be adjustable in height and/or in length, in order tobe able to determine or vary the thickness or the size of therectangular recess or the width of the recess and thus the width of thearea of the foil according to the invention with the second color.

[0024] The orifice of the second molding tool can have a cross sectionextending cross-wise vis-a-vis the flow direction of the plastic melt,which corresponds approximately to the protrusion or the lip.

[0025] The interior cross-section of the orifice of the second and/oreach additional molding tool is adjustable or variable in accordancewith the selected adjustment of the projection or the lip of the firstmolding tool, so that an inside cross-section of the orifice of thesecond or each additional molding tool can be adjusted in accordancewith the modified cross-section of the depression of the carrier foil.

[0026] According to a further beneficial specific embodiment, at leastone device is provided for preheating at least one of the foils orlayers before the calender. The temperature of said heating device isselected conditional upon the properties of the to be heated foil, suchas for example thickness and type of the thermoplastic syntheticmaterial. The preheating preferably takes place by means of an IRradiant [heating] field.

[0027] Further beneficial refinements of the invention are apparent fromthe sub claims 2 to 6, 8 to 17 and 20.

[0028] Additional benefits, beneficial refinements and applicationpossibilities of the present invention are apparent from the descriptionwhich follows with regard to specific embodiments of the invention inconnection with the enclosed drawings.

[0029]FIG. 1 shows a schematic lateral view of a first specificembodiment of the device according to the invention, seen in thedirection of the arrow I of FIG. 2.

[0030]FIG. 2 shows a top view of FIG. 1 in the direction of the arrowII;

[0031]FIG. 3 shows a schematic lateral view of a second specificembodiment of the device according to the invention, seen in thedirection of arrow III of FIG. 4.

[0032]FIG. 4 is a top view in the direction of arrow IV of FIG. 3;

[0033]FIG. 5 is a schematic cross-section of the first molding tool ofthe device according to the invention in accordance with FIG. 1, seen inthe direction of arrow V of FIG. 1 (rotated by 90 degrees in clock-wisedirection vis-a-vis the position in FIG. 1);

[0034]FIG. 6 shows a schematic cross-section of the second molding toolsof the device according to the invention in accordance with FIG. 1, seenin the direction of arrow VI of FIG. 1;

[0035]FIG. 7 shows a schematic cross-section of the first specificembodiment of the foil according to the invention, produced with thedevice of FIGS. 1 and 2 or the device of FIGS. 3 and 4 seen in thedirection of arrow VII of FIG. 4;

[0036]FIG. 8 shows a schematic cross-sectional view of a second specificembodiment of the foil according to the invention with two colors,whereby the carrier layer is visible as a strip between the top layer;and

[0037]FIG. 9 shows a schematic cross-sectional view of a third specificembodiment of the foil according to the invention with three colors,which are visible as three adjacent paths or strips.

[0038] In FIGS. 1 and 2, a first specific embodiment of the deviceaccording to the invention is shown schematically, which basicallycomprises a first extruder device 20 or an extruder with a first moldingtool 22, a second extruder device 24 with a second molding tool 26, anda calender. The first specific embodiment of the device according to theinvention is designed for manufacture of a foil 14 of plastic, which ismade up of a carrier foil or carrier layer 10 and a top layer or topfoil 12. Instead of the second extrusion device 24 there may, however,also be provided an inventory of an already finished top layer or topfoil 12.

[0039] The first extrusion device 20 has the usual construction of anextrusion implement and comprises, among others, a feeding screw (notshown) which is charged, at the input side, with synthetic granulate,which is being plastified and homogenized into a viscous molding massduring transport via the screw, under addition of heat and by means ofpressure developed in the screw. The molding mass of the plastic melt isextruded by the extruder 20 via a first molding tool with integrateddischarge orifice or sheet orifice (not shown) as carrier foil orcarrier layer 10. The carrier foil 10 has a first color 28 fromappropriate addition of dye or color pigmentation, which may have, forexample, a dark, black or gray color shade.

[0040] The second extruder device 24 is constructed identically orsimilar to the first extruder device 20 and extrudes a synthetic melt ormolding mass by means of a second molding tool 26 with exit orifice (notshown) as top foil or top layer, which has a second color 30 with adifferent shade from the first color 28, for example a light or whitecolor shade.

[0041] The first molding tool 22 is arranged at the first extruderdevice 20 and is shown in cross-section in FIG. 5 (compare V in FIG. 1).The first molding tool 22 has a molding chamber 21, into which entersthe synthetic melt via a channel 23, originating from the extruderdevice 20, and a generally rectangular slot-like inside cross-section.Into chamber 21 projects a lip 34 as protrusion, which has aright-angled cross-section and serves for forming a right-angled recessas depression 16 in the carrier foil 10 formed by the first molding tool22. The chamber 21 of the molding tool 22 verges at the discharge sidein the direction of the flow of the synthetic melt into a dischargeorifice (not shown).

[0042] The second molding tool 26 is arranged at the second extruderdevice 24 and is shown in cross-section in FIG. 6. It has a moldingchamber 25 which has a right-angled inside cross-section. The chamber 25of the second molding tool 26 can be supplied on the inlet side via achannel 27 with the synthetic melt or molding mass from extruder 24.Chamber 25 passes on the exit side into the extrusion opening of thedischarge orifice (not shown) of the molding tool 26. The right-angledinside cross-section of chamber 25 of the second molding tool 26 isadapted to or congruent with the right-angled cross-section of the lip34 protruding into the chamber 21 of the first molding tool 22. Thesecond molding tool 26 produces the top foil or top layer withrectangular, slot-like thickness profile.

[0043] The calender 32 of the first specific embodiment of the deviceaccording to the invention comprises three next to each other arrangedrotating cylinders 36, 38 and 40. The rotational direction of thecylinders is indicated with corresponding arrows in FIG. 1.

[0044] The first cylinder 36 rotates in clock-wise direction, whereasits adjacent second cylinder 38 rotates in counterclockwise direction.Between the first cylinder 36 and the second cylinder 38 there is a feedslot 42, in whose region the first cylinder 36 and the second cylinder38 collect and pull in the carrier layer 10 and the top layer 12. Asindicated in FIG. 1, the first molding tool 22 with its exit opening isarranged above the feed slot 42 in such manner that the carrier layer 10extruded by the extruder device 20 and the molding tool 22, enters thefeed slot 42 vertically or perpendicular, coming from the top. The toplayer 12, extruded by the second extruder device 24 and the secondmolding tool 26 extends, on the other hand, initially in a horizontalplane, as is shown in FIG. 1, and is then transported by the firstcylinder 36 and, positioned on its cylinder circumference, is conductedto the feed slot 42. The second molding tool 26 is arranged in suchmanner that the top layer, correctly positioned or adjusted in positionrelative to the carrier layer 10, enters the feed slot 42 between thefirst cylinder 36 and the second cylinder 38, whereby the top layer 12enters, exactly congruent, into the rectangular recess or depression 16of the carrier layer 10.

[0045] The first cylinder 36 and the second cylinder 38 transport thejoined carrier layer 10 and top layer 12 until the composite foil leavesagain the calender 32 via the third cylinder 40, which rotates inclock-wise direction.

[0046] As a result of the temperatures prevailing in the calender,ranging between 40 to 90° C. and the pressure exercised by the cylinder,the foils are fused together or glued together to form a solid compositeand, concurrently, the surface of the developing composite foil is beingsmoothed out.

[0047] The method according to the invention, which is executed with thefirst specific embodiment of the device in accordance with the inventionaccording to FIGS. 1 and 2, thus starts with the manufacture of acarrier foil or carrier layer 10 which, in essence, has a rectangularslot-like thickness profile, in which a depression 16, here arectangular recess, is formed along the entire longitudinal extension ofthe carrier layer 10, by the lip 34 of the molding tool 22.

[0048] Concurrently with the manufacture of the carrier layer 10, a toplayer 12 is produced by means of extrusion and shaping, whose thicknessprofile is rectangular and slot-like.

[0049] The top layer 12 fits congruently into the depression 16 or therectangular recess of the carrier layer 10.

[0050] The carrier layer 10 and the top layer 12 are then joined in acalender 32 by means of pressure and heat, so that a stable composite isformed from the carrier layer 10 and the top layer 12, which is issuedfrom the calender 32 as composite foil 14 according to the invention.The joining or bonding of the carrier layer 10 and the top layer 12 isdone in the area of the feed slot 42 of the calender 32, whereby thecarrier layer 10 and also the top layer 12 are conducted from thegeometric site of their manufacture or shaping in such manner to thefeed slot 42, that the top layer 12 is fitted or inserted in properposition into the depression 16 or the rectangular recess of carrierlayer 10.

[0051] As a result of the pressure exercised by the cylinders, thesurface of the composite foil is, furthermore, smoothed out.

[0052] It is possible, to provide by way of at least one of the foils orlayers of the extruder device to the calender a device for preheatingthe corresponding foil, in order to prepare same in suitable manner forthe subsequent process of joining or bonding.

[0053]FIGS. 3 and 4 show a second specific embodiment of the deviceaccording to the invention, schematically. The second specificembodiment comprises a first extruder device 20.1 and a second extruderdevice 24.1, which have the same construction and the same function asthe first and second extruder device 20 and 24 of the first specificembodiment of FIGS. 1 and 2.

[0054] At the output side, the extruder devices 20.1 and 24.1 areconnected, flow-wise, with a forming block 44, which is arranged at thetwo extruder devices 20.1 and 24.1. The forming block 44 comprises inintegrated fashion the first molding tool 22, according to FIG. 5 of thefirst specific embodiment and also the second molding tool 26 of thefirst specific embodiment of the device according to the invention.Integrated into forming block 44 is, however, the second molding tool 26of FIG. 6 instead of the lip 34 of the first molding tool 22 of FIG. 5(not shown) in order to produce and join in the forming block 44 boththe carrier layer 10 with rectangular recess, as well as the top layer12 with rectangular, slot-lite cross-section 12. From an outlet orifice(not shown) of forming block 44 then exits a composite of carrier layer10 and top layer 12.

[0055] As is evident from FIG. 3, said composite of carrier layer 10 andtop layer 12, coming from forming block 44 is conducted to calender32.1, which, in turn, has three cylinders 36.1, 38.1 and 40.1, arrangednext to each other, whose axes are parallel to each other and arepositioned in a common horizontal plane. The composite foil exiting fromthe forming block reaches the first cylinder 36.1 in horizontalorientation and is then introduced on part of the cylinder circumferenceof the first cylinder 36.1 into a feed slot 42.1. The first cylinder36.1 and the second cylinder 38.1 seize the composite and convey itfurther into the gap between the second cylinder 38.1 and the thirdcylinder 40.1 which issue the foils as composite foil 14 after joiningor bonding and smoothing of the developing surface.

[0056] The produced foil 14 is, in turn, two-colored. It shows on itstop side 48 a first color 28, with which the carrier layer has beendyed, and a second color 30, with which the top layer 12 has been dyed.

[0057] With the alternative mode of the method according to theinvention, which is executed with the second specific embodiment of thedevice in accordance with the invention according to FIGS. 3 and 4, thecarrier layer 10 and the top layer 12, in contrast to the first specificembodiment according to FIGS. 1 and 2, are not just joined in the feedslot 42.1 of the calender 32.1 of the second specific embodiment, butare joined immediately following the shaping of the carrier layer 10 andthe top layer 12, in the integrated forming block 44, so as to leavealready as a composite the forming block 44. Said composite of carrierlayer 10 and top layer 12 is then pulled into the feed slot 42.1 of thecalender 32.1 and is further processed, so that a plastic foil 14 isobtained after smoothing, which is identical to the plastic foilproduced with the first specific embodiment of the device in accordancewith the invention, according to FIGS. 1 and 2.

[0058] The construction of the foil 14 of thermoplastic materialproduced with the first and second specific embodiment of the deviceaccording to the invention is shown schematically in cross-section inFIG. 7. It is clearly apparent from FIG. 7 that the carrier layer 10 offoil 14 up to the top side 48 of foil 14 and also the top layer 12 whichis fitted into the depression 16 or into the rectangular recess ofcarrier layer 10, reaches up to the top side 48 of foil 14. The top side12 and the carrier layer 10 have a flush surface at the top side 48 offoil 14. Since the carrier layer 10 has a first color 28 and the toplayer 12 has a second color 30, which are different from each other, forthe person looking at them, the top side 48 of foil 14 has a two-coloredappearance.

[0059]FIG. 8 shows a second exemplary specific embodiment of the plasticfoil according to the invention. Foil 14.1 of the second specificembodiment comprises again one carrier foil 10.1 with a color 28, and atop layer 12.1 which consists of two strips extending parallel to eachother, separated from each other at the top side 48.1 of foil 14.1.

[0060] The strips of top layer 12.1 are arranged or fitted intocorresponding rectangular recesses or depressions 16.1. With foil 14.1the carrier layer also reaches up to the top side of foil 14.1. Theforming tools employed for shaping the carrier layer 10.1 and the toplayer 12.1 are designed accordingly for producing the foil 14.1.

[0061]FIG. 9 shows a third exemplary specific embodiment of the foilaccording to the invention. The foil 14.2 again comprises a carrierlayer 10.2, which has a depression 16.2 or a rectangular recess. Intosaid depression 16.2 are fitted or inserted next to each other a firstrectangular top layer 12.2 and a second rectangular top layer 12.3. Thecarrier layer has the color 28, the first top layer 12.2 has the color30 and the second top layer 12.3 has the color 31. Colors 28, 30, 31 aredifferent from each other. The carrier layer 10.2 reaches again up tothe upper side 48.2 of foil 14.2, whereby the carrier layer 10.2, thefirst top layer 12.2 and the second top layer 12.3 have a flush surfaceat the top side 48.2.

[0062] Foil 14.2 thus has a 3-color aspect at the top side 48.2.

We claim:
 1. Method for manufacturing a multi-colored, specifically atwo-colored composite foil (14; 14.1; 14.2) of thermoplastic syntheticmaterial characterized by the following process steps: manufacture of acarrier foil or carrier layer (10; 10.1; 10.2) of a first color byextruding a thermoplastic synthetic material while forming at least onedepression (16; 16.1, 16.2) in the thickness profile of the carrier foilor the carrier layer; joining of at least one top foil or top layer (12;12.1, 12.2; 12.3) whose color is different from the named first color,whereby at least one top layer is formed in such manner that it fitssurface-flush into the depression of the carrier layer or the carrierfoil (10; 10.1; 10.2), and insertion of at least one top foil or toplayer into the corresponding depression of the carrier layer or carrierfoil and bonding of layers under the influence of heat and pressure withconcurrent smoothing of the developing surface so that a multi-coloredcomposite foil (14; 14.1; 14.2) is formed with flush surface.
 2. Methodaccording to claim 1, characterized in that the top foil or the toplayer (12) is produced simultaneously with the carrier foil or carrierlayer (10).
 3. Method according to claim 1 or 2 characterized in thatthe carrier foil or the carrier layer (10) is formed with a rectangularthickness profile and with a depression (16) in the shape of a recesswith rectangular cross-section and the top layer or top foil (12) isformed with a thickness profile having the shape and size of therectangular recess of the carrier layer or the carrier foil (10). 4.Method according to at least one of claims 1 to 3, characterized in thatthe carrier layer or carrier foil (10; 10.1; 10.2) and at least the onetop layer or top foil (12; 12.1; 12.2; 12.3) are produced ofthermoplastic synthetic materials whose viscosities approximatelycorrespond to each other at identical temperatures.
 5. Method accordingto one of claims 1 to 4, characterized in that at least one of the foilsor layers is preheated prior to the step of joining or bonding. 6.Method according to one of claims 1 to 5, characterized in that thesurface of the composite foil is smoothed out at least one more time. 7.Device for producing a multi-colored, specifically two-colored,composite foil (14; 14.1; 14.2) having a first extruder device (20;20.1) for producing a plastified synthetic material melt, said extruderdevice being equipped with a first forming tool (22) for shaping acarrier foil or carrier layer (10; 10.1; 10.2) a first color (28) whiledeveloping at least one depression (16; 16.1; 16.2) and a calender (10;10.1; 10.2) with at least one top layer or top foil (12; 12.1; 12.2;12.3) fitted into the corresponding recess (16; 16.1; 16.2) of thecarrier layer or carrier foil (10; 10.1; 10.2) in a color different fromthe named first color (31) and for smoothing out the developed surface.8. Device according to claim 7, characterized in that at least oneadditional extruder device (24, 24.1) is provided for producing at leastone additional plastified synthetic material melt, whereby at least theone additional extruder device is respectively equipped with anotherforming tool (26) for shaping of the top foil or top layer (12; 12.1;12.2) whereby at least the one additional forming tool is designed insuch manner that the top layer or top foil (12), shaped with same,respectively fits, surface-flush, into the corresponding depression (16;16.1,16.2) of the carrier layer or the carrier foil (10).
 9. Deviceaccording to claim 7 or claim 8, characterized in that the first formingtool (22) has a slot-like orifice, into which projects a protrusionwhose cross-section, extending cross-wise to the flow direction of theplastic material melt corresponds to the cross-section of the depression(16; 16.1; 16.2) of the manufactured carrier layer or carrier foil 10;10.1; 10.2).
 10. Device according to claim 9, characterized in that theprotrusion is arranged adjustably in the first forming tool (22) inorder to be able to adjust the form and the size of the depression (16;16.1; 16.2) in the carrier foil or the carrier layer.
 11. Deviceaccording to claim 9 or claim 10, characterized in that the protrusionhas the shape of an elongated lip (34) or lamella.
 12. Device accordingto claim 11, characterized in that the lip (34) is adjustable in heightand/or length.
 13. Device according to one of claims 9 to 12,characterized in that at least the one additional forming tool (26) hasan orifice whose inside cross-section corresponds approximately to thecross-section of the protrusion of the first forming tool (22). 14.Device according to claim 13, characterized in that the orifice of atleast the one additional forming tool (26) has a slot-likecross-section.
 15. Device according to one of claims 7 to 14,characterized in that the calender (32; 32.1) has several, specifically3, successively arranged cylinders (36, 38, 40; 36.1, 38.1, 40.1) whoseaxes lie in one plane, whereby at least two of the cylinders of thecalender collect the carrier layer or carrier foil and at least the onetop foil or top layer in a feed slot (42, 42.1).
 16. Device according toone of claims 8 to 15, characterized in that the first forming tool andat least the one additional forming tool are integrated into a formingblock (44) which is arranged before the calender (32.1) for simultaneousshaping of at least the one top layer or top foil (12; 12.1; 12.2; 12.3)and the carrier layer or carrier foil (10; 10.1; 10.2), so that at leastthe one top layer can be fitted into the corresponding depression (16;16.1; 16.2) of the carrier layer, so that the foils are leaving theforming block (44) joined into a composite.
 17. Device according toclaim 16, characterized in that the forming block (44) has a slot-likeexit orifice and that the first forming tool (22) and at least the oneadditional forming tool (26) are arranged in such manner in front of theexit orifice that the carrier layer or carrier foil (10) and at leastthe one top layer or top foil (12) applied on the carrier layer orcarrier foil will enter the exit orifice together and reach the calender(32.1) as composite.
 18. Device according to one of claims 7 to 17,characterized in that at least one device is provided for preheating ofat least one of the foils or layers before the calender.
 19. Compositefoil of thermoplastic synthetic material, which consists of a compositeof one carrier layer or carrier foil (10, 10.1; 10.2) and at least onetop layer or top foil (12; 12.1; 12.2; 12.3), characterized in that atleast the one top layer or top foil is fitted into a correspondingdepression (16; 16.1; 16.2) of the carrier layer or carrier foil (10;10.1; 10.2) and that the carrier layer or carrier foil and at least theone top layer or top foil (12; 12.1; 12.2, 12.3) respectively form partof the top side (48; 48.1; 48.2) of the foil (14; 14.1; 14.2), wherebythe colors (28, 30, 31) of the carrier layer or the carrier foil and atleast the one top layer or top foil are different from each other. 20.Foil according to claim 19, characterized in that the depression (16) inthe carrier foil or carrier layer (10) is a rectangular recess.